Methods for making wirebound box and crate mats



June 10, 1958 w. F. NEwHous; 2,837,744

METHODS FOR MAKING WIREBOUND BOX AND CRATE MATS Filed Dec. 5, 1956 INVENTOICI WALTER E NEWHOUSE 2 Sheets-Sheet 1 M7 WQLM June 10, 1958 w. F. NEWHOUSE 2,337,744

METHODS FOR MAKING WIREBOUND BOX AND CRATE MATS I Filed Dec. 5, 1956 2 Sheets-Sheet 24 FIG.4

- INVENTOR: WALTER F. NEWHOUSE ATT'YS METHODS FOR MAKING WIREBOUND BOX AND CRATE MATS This invention relates to methods for making wirebound box and crate mats of the type embodying encircling wires stapled to the cleats or slats of the box or crates.

The crate mat formed by the method of the present invention serves as the body of a box or crate of the wirebound type, and may be used in the form of a mat to be wrapped around the base or pallet of the crate or in the form of a tube. The completed crate body comprises a plurality of spaced apart panels which are hingedly connected together by encircling binding wires. Initially, a plurality of cleats are placed in parallel spaced relation at one station; Certain slats, such as intermediate or corner slats are then positioned over the cleats at one or more successive stations. The crate is continuously made by a machine having a plurality of successive stations, each of which serves to perform a certain function in the continuous making process.

Cleat guides and pushers maintain the cleats in proper position, while slat fingers maintain the slats in proper position. Binding wires are then fed along the cleats and over the slats which will later serve to hingeldly connect these various panels together. In one embodiment, certain other slats are then positioned over the cleats and 'over the binding wire at another successive station and the assembled parts are advanced under staplers which are in alignment with the cleats and which serve to drive staples in straddle relation over the wires and secure the wires to the cleats as well as securing the slats and cleats together. As the panels continue to pass through the wirebound box-making machine, at another station cutters are operated at predetermined times to cut or sever the wire a predetermined distance beyond the last panel. In another embodiment, staples are driven into the cleats and in straddle relation to the binding wires before the last set of slats are positioned over the cleats.

Accordingly, it is an object of this invention to provide an improved method for making wirebound box and crate mats.

Another object of this invention is in the provision of a method for making a wirebound box or crate mat which isstrong and durable in construction, and which may be made in a'continuous operation.

' A still further object of this invention resides in the provision of a method for making a wirebound box or crate mat having hingedly connected panels which may be formed as a tube, wherein each panel is rigid and durable in construction and capable of being readily and eco nomically manufactured, and wherein the completed mat in tube form may be easily and compactly collapsed for storing purposes.

Another object of this invention is to provide a plurality of successive stations arranged to perform successive operations for continuously making crate mats.

Gtherobjects, features, and advantages of the invention will-be apparent from the following detailed disclosure, taken "in conjunction with the accompanying tates Patent ice ' sheets of drawings, wherein like reference numerals refer to like parts in which:

Fig. 1 is a perspective view illustrating certain steps of making wirebound boxes and crate mats in accordance with the invention, and showing some parts of the box making machine schematically;

Fig. 2 is a perspective view of the finished crate mat made in accordance with the invention;

Fig. 3 is a greatly enlarged view in section taken through one end of a panel of the crate mat constructed in accordance with the present invention, illustrating the arrangement of the binding wire; I

Fig. 4 is a somewhat schematic and fragmentary side elevational view of the arrangement shown in Fig. 1 and illustrating the hold down means positioned ahead of the stapling units;

Fig. 5 is a broken top plan view of the portion of the arrangement of Fig. 1 showing the pusher dogs engaging the cleats and slats and positioning same and the guide rails as well as the side aligning rollers; and

Fig. 6 is a more or less diagrammatic view, in side elevation, of a modified method of forming a wire box or crate mat in accordance with the invention.

Wirebound box or crate mats are made in accordance with the present invention in one continuous operation by a wirebound box and crate making machine as disclosed in appli'cants copending application Serial No. 626,473, filed December 5, 1956. A plurality of successive stations are arranged to form a plurality of successive operations. The completed crate mat includes a plurality of panels hingedly connected together by encircling binding wires, wherein each panel may include a plurality of outside cleats, and a plurality of inside corner and/or intermediate slats. The binding wire may extend between the inner faces of the cleats and the outer faces of some the slats and over the inner faces of other slats thereby forming a rigid and durable structure.

The completed crate mat it formed by the method of the present invention may include any number of panels hingedly connected together by encircling binding wires, but for purposes of illustrating the invention, the crate mat will include four panels 11, 12, 13, and 14 as seen in Fig. 2. It will be noted that the panels 11 and 13 are substantially identical in size and form, while the panels 12 and 1d are substantially identical in size and form.

These four panels are formed continuously by crate making machinery, the panels being spaced a predetermined distance apart.

Each of the panels in Fig. 2 is shown as comprising spaced-upper and lower outside cleats 15 and 16 to which vertical end or corner slats 1'7 and 18 are fastened. A pair of intermediate crossed bracing slats 19 may also be secured to the cleats 15 and i6, and a vertical intermediate bracing slat 20 may also be secured at one side of the crossed slats to the upper and lower outside cleats 15 and 16. Intermediate outside cleats 21 and 22 may be applied exteriorly of the slats 17 to 20, although the cleats may be omitted on smaller size crates. The slats 17 to 20 have their outer surfaces facing the inside surfaces of the outer cleats 15, 16, 2t and 22 in physical contact there- With.

The four panels are hingedly connected together by spaced binding wires 23, 24, 25, and 26 which are in alignment with the cleats 15, 21, 22, and 16, respectively. The binding wires 23 and 26 may be termed the upper and lower binding wires, while the binding wires 24 and 25 may be termed the intermediate binding wires. The free ends of each of the binding wires extend a predetermined distance beyond the ends of the outer or end panels 11 and 14, and are adapted to be connected in any convenient manner such as by twisting them together (not shown). Each of the binding wires is arranged between the outer faces of the corner slats and the inner faces of the cleats and along the inner faces of the intermediate bracing slats 19 and 20. Locking or fastening staples 27 are arranged on the inner faces of the corner slats 17 and 18, and the intermediate slats 19 and 20, and straddle the wires 23, 24, 25, and 26 having their legs entering the cleats, preferably all the way through and being clinched on the outer faces of the cleats. Thus, the staples securely lock the binding Wires in proper position, prevent any slippage of the binding wires, provide for a smoother interior surface of the crate, and still maintain the proper folding corners to allow the crate to be fully and completely folded and collapsed.

The panel 11 is shown as being identical in shape, size, and construction with its oppositely disposed panel 13, while the panel 12 is shown as being identical in size, shape and construction with its oppositely disposed panel 14. It will be noted that the upper and lower cleats 15 and 16 of the panels 12 and 14 are wider than the upper and lower cleats 15 and 16 of the panels 11 and 13; and that the slats of panels 12 and 14 are longer than the slats of panels 11 and 13, although the relative sizes may be identical in some cases, if desired.

It is desirable that the crate mat be folded absolutely fiat so as to conserve space in shipping and storing. It is further desired that no undue tension or strain be placed on the binding wires during the normal folding of the connected panels 11 to 14 into a tubular crate formation. Therefor, in order to make a crate which will lie absolutely flat when folded, adjacent corner slats of the panels 12 and 14 should be such that the free length of binding wire therebetween is greater than the free length of binding wire between panels 11 and 12 and 13 and 14 to form a folding corner 28. in order to accomplish this, the corner slat 17 of the panel 12 and the corner. slat 18 of the panel 13 are spaced a slight distance inward from the ends of the adjacent cleats. The total increased free length of wire at the folding corner is equal to twice the thickness of a corner slat; and therefore, the corner slats at the locking corner are each spaced inwardly a distance from the adjacent ends of the cleats a distance equal to the thickness of a corner slat. Similarly, the panels at the locking corner of the crate mat where the free ends of the binding wires will be twisted together, will be spaced apart a distance substantially equal to the free length of the wires at the folding corner 28 in order to allow the crate mat to be folded properly in collapsed position.

The method of making the crate mats according to the invention includes the utilization of a plurality of successive stations A, B, C, D, E, F, G, H, I, and I, as seen in Fig. 1. Certain operations are performed at each station wherein the various parts are advanced along a horizontal surface by an endless conveyor as seen in my copending application Serial No. 626,473, filed December 5, 1956.

Initially, the cleats 15, 21, 22 and 16, for each panel, are arranged in parallel extending relationship at station A. These cleats are then advanced towards the right to station B where the intermediate bracing slat 20 is positioned transversely of the cleats. Once the cleats have passed to station B, another set of cleats 15, 21, 22, and 16 are arranged behind the first set of cleats. Thus, it is seen that the cleats of successive panels are also arranged in end-to-end relation with each other and spaced at predetermined distance apart. At station C, one of the intermediate bracing slats 19 is positioned over the cleats, while at station D the other intermediate slat 19 is placed over the cleats.

The panels are then successively advanced under the cross shaft 29 having spaced apart grooved rollers, 30, 31, 32, and 33 secured thereon. These rollers serve to guide the feeding of binding wires at station E onto the panels of the crate mat. Inasmuch as it is desired that the binding wires align with a longitudinal axis of each cleat, the grooved rollers will be accordingly positioned along the cross shaft 29 so that the binding wires will be fed directly over the approximate longitudinal center of the cleats. The binding wires initially contact the leading edge of the cleats, then drop over the intermediate bracing slats, and finally contact the inner surfaces of the trailing edges of the cleats. At station F, the leading corner slat 18 is arranged across the cleats and over the binding Wires, sandwiching the binding wires with the coaction of the cleats. The trailing corner slat 17 is then placed in position when the panel reaches the station G. Station H includes means for properly aligning the cleats or slats together ahead of the stapling or fastening operation.

The panels are then successively advanced under transversely spaced staplers 34, 35, 36, and 37, which are aligned with the cleats to drive staples through the slats and cleats. The staples are clinched on the outer faces of the cleats in order to securely lock the cleats, binding wires and slats together. Further, it may be noted that the legs of the staples are aligned in straddle relation with the binding wires 23, 24, 25, and 26. Hence, the

stapling or fastening operation is accomplished at the station 1.

Between the first and last panels of adjacent crate mats, a relatively wide space is provided such as indicated by the numerals 38 and 39, Fig. l, in order to provide sufficient wire to extend beyond each end panel of a mat. In order to separte the crate mats from each other, scissors-type cutters 4t), 41, 42, and 43 are automatically actuated to sever or cut the wires at station I when the spaces reach this station. A separated and completed crate mat will appear as that shown in Fig. 2. In order to maintain the cleats in proper parallel alignment during their movement through the various successive sta tions, longitudinally extending guide rails 44, 45, 46, and 47 extend along the horizontal supporting surface. Pusher dogs 48 serve to advance the cleats along the supporting surface and maintain successive sets of cleats in spaced relationship. These pusher dogs are attached to endless chains as more clearly set forth in my copending application Serial No. 626,473, filed December 5, 1956. Some of the pusher dogs have flat engaging' fingers thereon which serve to guide the arrangement of the slats over the cleats and maintain them in proper spaced relationship. All of the pusher dogs further serve to coact with the opposing guide rail to maintain the cleats in proper longitudinal alignment during the travel from station to station.

As seen most clearly in Fig. 4, hold down means 49 in the form of presser shoes, which are gravity actuated, engage the upper surfaces of the panels prior to their being advanced from station H to station I. These hold down shoes apply pressure to the upper slats and tend to create intimate contact between the slats, cleats and binding wires. 7

Another operation is performed at station H ahead of the stapling operation, wherein the opposite ends of the slats are aligned flush with the outer edges of the outermost cleats. This operation is performed by resiliently biased rollers 50, Fig. 5, which engage simultaneously the outer ends of the slats and the outer edges of the uppermost cleats. These aligning rollers are necessary, especially since some of the panels are of less width than others.

An alternative method of making a crate box or mat is illustrated in Fig. 6, wherein two banks of staplers 51 and 52 are arranged so that a stapling operation may be performed immediately after the binding wires are fed onto the panels by the staplers 51, but before the corner slats are arranged in position over the panels.

According to this method, the corner slats 17 and 18 are arranged on the panel after the intermediate bracing slats and the binding wires have been initially secured to the cleats. Subsequent to the arranging of the corner slats," the 7 panels are subjected to another stapling operationby' staplers 52 which then securethe corner-slats securely in position to the cleats and over the binding wires. 'It'will be understood thatthe initial stages of this method'of making the crateand mat are identical withgthe description in connectionwith the first embodiment. After these panels have advanced beyond the bankof staplers 52, the completed crate will appear substantially as'th-at shown in Fig. 2.

While the present invention has been described in connection with a crate mat having panels'with four cleats and ,five slats, it will beappreciated that any number of cleats or slats may be used depending upon the size of the crate matjdesired and other associated factors. Likewise, the number of binding wires employed will be that of a number of outer cleats employed. Further, the exact positioning of the binding wires with respect to the coner slats and the intermediate bracing slats may be altered in accordance with the desires of the particular installation.

It will be understood that modifications and variations may be effected without departing from the scope of the novel concepts of the present invention, but it is understood that this application is to be limited only by the scope of the appended claims.

The invention is claimed as follows:

1. A method of continuously making crate mats having hingedly connected panels which includes, continuously arranging at least a pair of cleats in parallel spaced relation at one station, continuously advancing the cleats along a flat surface to other successive stations, continuously feeding wires onto said cleats, continuously arranging at least a pair of slats over said cleats and said wires at another successive station, continuously fastening said cleats, slats and wires together at another successive station, and automatically cutting the wires at predetermined intervals to separate the mats from each other, after the completion of the fastening operation.

2. A method of continuously making crate mats having hingedly connected panels which includes, arranging a pair of cleats in substantially parallel spaced relation at one station, advancing the cleats to another successive station, feeding wires longitudinally onto said cleats, advancing the cleats and wires to another successive station, arranging a pair of slats over said cleats and wires, advancing the cleats, wires and slats to another successive station, fastening said cleats, slats and wires together, advancing the fastened parts to another successive station, and cutting the wires at predetermined intervals to separate the mats from each other.

3. A method of continuously making crate mats having hingedly connected panels which includes, continuously arranging a plurality of cleats in parallel spacedrelation at one station, continuously advancing the cleats along a flat surface to other successive stations, continuously feeding wires onto said cleats, continuously arranging a plurality of slats over said cleats and said wires at another successive station, continuously fastening said cleats, slats and wires together at another successive station, and automatically cutting the wires at predetermined intervals to separate the mats from each other after the completion of the fastening operation.

4. A method of continuously making crate mats having hingedly connected panels which includes, continuously arranging successive sets of cleats in parallel spaced relation at one station, continuously advancing each set of cleats to other successive stations, continuously feeding wires over said cleats and along the longitudinal axis of each cleat, continuously arranging successive sets of slats over said cleats and wires at another successive station, continuouly fastening said cleats, slats and wires together at another successive station, and severing the wires at predetermined intervals between certain adjacent panels to separate the mats fromeach other at the completion of the fastening operation.

5. Amethod of continuously making crate mats having hingedly connected panels whichincludes, continuously arranging successive-sets of cleats in parallel spaced relation at one station, continuously advancing each set of cleatsto other successive stations, continuously arranging successiveintermediate slatsgover said cleats at another successive station, continuously feeding wires over said cleats and intermediate slats and along the longitudinal axis of each cleat, continuously arranging successive sets of corner slats over said cleats and wires and in spaced relation to said intermediate slats at another successive station, continuously fastening said cleats, slats, and wires together at another successive station, and severing the wires at predetermined intervals between certain -adjacent panels to separate the mats from each other at the completion of the fastening operation.

6. A method of continuously making crate mats having hingedly connected panels which includes, continuously arranging successive sets of cleats in parallel spaced relation at one station, continuously advancing each set of cleats to other successive stations, continuously arranging successive intermediate slats over said cleats at another successive station, continuouly feeding wires over said cleats and intermediate slats and along the longitudinal axis of each cleat, continuously arranging successive sets of corner slats over said cleats and wires and in spaced relation to said intermediate slats at another successive station, and driving staples into said slats and cleats along said binding wires for securing said cleats, slats and binding wires together.

7. A method of continuously making crate mats having hingedly connected panels which includes, continuously arranging successive sets of cleats in parallel spaced relation at one station, continuously advancing each set of cleats to other successive stations, continuously arranging successive intermediate slats over said cleats at another successive station, continuously feeding Wires over said cleats and intermediate slats and along the longitudinal axis of each cleat, fastening said cleats, intermediate slats and wires together at another successive station, continuously arranging successive sets of corner slats over said cleats and wires and in spaced relation to said intermediate slats at another successive station, fastening said cleats, corner slats and Wires together at another successive station, and severing the wires at predetermined intervals between certain adjacent panels to separate the mats from each other at the completion of the fastening operation.

8. A method of continuously making crate mats having hingedly connected panels which includes, continuously arranging successive sets of cleats in parallel spaced relation at one station, continuously advancing each set of cleats to other successive stations, continuously arranging an intermediate slat over each successive set of cleats at another successive station, continuously arranging other intermediate slats over each successive set of cleats at other successive stations, continuously feeding Wires over said cleats and intermediate slats along the longitudinal axis of each cleat at another successive station, continuously arranging a corner slat over each successive set of cleats and adjacent one end thereof at another successive station, continuously arranging another corner slat over each successive set of cleats and adjacent the other end thereof at another successive station, continuously fastening said cleats, slats, and wires together at another successive station, and severing the wires at predetermined intervals between certain adjacent panels to separate the mats from each other at the completion of the fastening operation.

9. A method of continuously making crate mats having hingedly connected panels which includes, continuously arranging successive sets of cleats in parallel spaced relation at one station, continuously advancing each set of cleats to other successive stations, continuously feeding wires over said cleats and along the longitudinal axis of each cleat, continuously arranging successive sets of slats over said cleats and Wires at another successive station, continuously fastening said cleats, slats and wire together at another successive station, maintaining the cleats and slats in properly spaced relationship during movement through all of the stations, arranging the ends of said slats flush with the outer edges of the outermost cleats directly ahead of the fastening operation, and severing the wires at predetermined intervals between certain adjacent panels to separate the mats from each other at the completion of the fastening operaion.

10. A method of continuously making crate mats having hingedly connected panels which includes, continuously arranging successive sets of cleats in parallel spaced relation at one station, continuously advancing each set of cleats to other successive stations, continuously feeding wires over said cleats and along the longitudinal axis of each cleat, continuously arranging successive sets of slats over said cleats and wires at another successive station, continuously fastening said cleats, slats and wires together at another successive station, maintaining the cleats and slats in properly spaced relationship during movement through all of the stations, arranging the ends' of said slats flush with the outer edges of the outermost cleats directly ahead of the fastening operation, applying a downward pressure on said slats and cleats to urge them into intimate contact with each other before the fastening operation, and severing the wires at predetermined intervals between certain adjacent panels to separate the mats from each other at the completion of the fastening operation.

No references cited. 

